Hino j05d, j08e Service Manual
For DENSO Authorized
ECD Service Dealer Only
Diesel Injection Pump
SERVICE MANUAL
Common Rail System for HINO
J05D/J08E Type Engine
OPERATION
October, 2003
-1
00400041E
TABLE OF CONTENTS
1. Product Application ------------------------------------------------------------------------------------- 1
1.1 Application ------------------------------------------------------------------------------------------------------------------- 1
1.2 System Components Parts Numbers --------------------------------------------------------------------------------- 1
2. Outline ------------------------------------------------------------------------------------------------------ 2
2.1 Features of System ------------------------------------------------------------------------------------------------------- 2
[1] System Characteristics ------------------------------------------------------------------------------------------------ 2
[2] Comparison to the Conventional System ------------------------------------------------------------------------- 3
2.2 Outline of System ----------------------------------------------------------------------------------------------------------4
[1] Composition -------------------------------------------------------------------------------------------------------------- 4
[2] Operation ----------------------------------------------------------------------------------------------------------------- 4
2.3 Fuel System and Control System -------------------------------------------------------------------------------------- 5
[3] Fuel System -------------------------------------------------------------------------------------------------------------- 5
[4] Control System ---------------------------------------------------------------------------------------------------------- 5
3. Construction and Operation--------------------------------------------------------------------------- 6
3.1 Description of Main Components ------------------------------------------------------------------------------------- 6
[1] Supply Pump (HP3, HP4) --------------------------------------------------------------------------------------------- 6
[2] Description of Supply Pump Components ------------------------------------------------------------------------ 13
[3] Rail -------------------------------------------------------------------------------------------------------------------------- 16
[4] Injector (G2 Type) ------------------------------------------------------------------------------------------------------- 17
[5] Engine ECU (Electronic Control Unit) ------------------------------------------------------------------------------ 22
3.2 Description of Control System Components ------------------------------------------------------------------------ 22
[1] Engine Control System Diagram ------------------------------------------------------------------------------------ 22
[2] Sensor and Relays ----------------------------------------------------------------------------------------------------- 23
3.3 Various Types of Controls ----------------------------------------------------------------------------------------------- 29
[1] Fuel Injection Rate Control ------------------------------------------------------------------------------------------- 30
[2] Fuel Injection Quantity Control --------------------------------------------------------------------------------------- 31
[3] Fuel Injection Timing Control ----------------------------------------------------------------------------------------- 35
3.4 Other Relevant Engine Control ----------------------------------------------------------------------------------------- 36
[1] EGR Control -------------------------------------------------------------------------------------------------------------- 36
3.5 Engine ECU -----------------------------------------------------------------------------------------------------------------37
[1] Diagnosis Codes -------------------------------------------------------------------------------------------------------- 37
[2] ECU External Wiring Diagram --------------------------------------------------------------------------------------- 44
[3] ECU Connector Diagram ---------------------------------------------------------------------------------------------- 45
0
1. Product Application
1.1 Application
Vehicle Name Vehicle Model Engine Model Exhaust Volume Reference
HINO145, HINO165,
HINO185
J05D 4.73L
Medium Truck
HINO238, HINO268,
HINO308, HINO338
J08E 7.68L
1.2 System Components Parts Number
Part Name
Supply Pump
Vehicle
Name
DENSO Part
Number
294050-0011 22730-1311A
Car Manufacturer
Part Number
Injector 095000-5281 23910-1360A
Rail 095440-0480 22760-1180A
Engine ECU 102758-3010 89560-6540A
Accelerator Position Sensor 198800-3160 78010-1200A
Coolant Temp. Sensor 071560-0110 83420-1250A
Crankshaft Position Sensor 029600-0570 89410-1280A
Cylinder Recognition Sensor 949979-1360 89410-1590A
Medium Truck
HINO238,
HINO268,
HINO308,
HINO338
Sales from
Early ’04
Reference
Intake Air Pressure Sensor 079800-5890 89390-1080A
EGR Valve 135000-7091 17350-1220A
Air Flow Meter 197400-2000 22204-21010B
Supply Pump
294000-0251 22730-1321A
Injector 095000-5391 23910-1310A
Rail 095440-0530 22760-1220A
Engine ECU 102758-3010 89560-6540A
Accelerator Position Sensor 198800-3160 78010-1200A
Coolant Temp. Sensor 071560-0110 83420-1250A
Crankshaft Position Sensor 029600-0570 89410-1280A
Medium Truck
HINO145,
HINO165,
HINO185
Cylinder Recognition Sensor 949979-1360 89410-1590A
Intake Air Pressure Sensor 079800-5890 89390-1080A
EGR Valve 135000-7071 17350-1210A
Air Flow Meter 197400-2000 22204-21010B
For EGR
Control
For EGR
Control
1
2. Outline
2.1 Features of System
The common rail system was developed primarily to cope with exhaust gas regulations for
diesel engines, and aimed for 1. further improved fuel economy; 2. noise reduction; and 3.
high power output.
[1] System Characteristics
The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain electronically controlled solenoid valves to spray the pressurized fuel into the cylinders. Because the engine ECU controls the injection system
(including the injection pressure, injection rate, and injection timing), the system is unaffected
by the engine speed or load. This ensures a stable injection pressure at all times, particularly
in the low engine speed range, and dramatically decreases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas
emissions are cleaner and reduced, and higher power output is achieved.
(1) Injection Pressure Control
a. Enables high-pressure injection, even in the low engine speed range.
b. Optimizes control to minimize particulate matter and NOx emissions.
(2) Injection Timing Control
a. Optimally controls the timing to suit driving conditions.
(3) Injection Rate Control
a. Pilot injection control sprays a small amount of fuel before the main injection.
Common Rail System
Injection Pressure Control
Optimization, High Pressurization
Common Rail System
Conventional
Injection Pressure
Pump
Speed
Particulate
Injection
Pressure
Injection Timing Control
Optimization
Common Rail System
NOx
Injection Timing
Conventional
Pump
Speed
Injection Rate Control
Pilot Injection
Injection Rate
Crankshaft Angle
Injection Quantity Control
Cylinder Injection
Volume Correction
Speed
㧝㧟㧠㧞
Main
Injection
(4) EGR (Exhaust Gas Recirculation) Control
a. By recirculating the exhaust gas into the intake side of the engine, the combustion
temperature is reduced and NOx is decreased.
2
QD0734E
[2] Comparison to the Conventional System
In-line, VE Pump
High-pressure Pipe
Momentary High Pressure
Timer
System
In-line Pump
VE Pump
Injection Quantity Control
Injection Timing Control
Pump (Governor)
Pump (Timer)
Rising Pressure
Distributor Pump
Injection Pressure Control
Dependent upon Speed and Injection Quantity
Governor
Pump
Common Rail System
Rail
Nozzle
Supply Pump
Usually High Pressure
Delivery Valve
Feed Pump
SCV (Suction Control Valve)
Injector
Fuel Tank
Engine ECU, Injector (TWV)*
Engine ECU, Injector (TWV)*
1
1
Engine ECU, Supply Pump
Engine ECU, Rail
Engine ECU, Supply Pump (SCV)*
*1 TWV: Two Way Valve *2 SCV: Suction Control Valve
TWV
2
QD2341E
3
2.2 Outline of System [1] Composition
The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.
Fuel Temperature Sensor
Vehicle Speed
Accelerator Opening
Intake Air Pressure
Intake Air Temperature
Coolant Temperature
Crankshaft Position
Cylinder Recognition Sensor
Intake Airflow Rate
Engine ECU
Rail Pressure
Sensor
Rail
Pressure
Limiter
Injector
Fuel Temperature Sensor
Supply Pump
SCV (Suction
Control Valve)
Fuel Tank
[2] Operation
(1) Supply pump (HP3)
a. The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the
rail. The quantity of fuel discharged from the supply pump controls the pressure in the
rail. The SCV (Suction Control Valve) in the supply pump effects this control in
accordance with the command received from the ECU.
(2) Rail
a. The rail is mounted between the supply pump and the injector, and stores the high-
pressure fuel.
(3) Injector (G2 type)
a. This injector replaces the conventional injection nozzle, and achieves optimal injection by
effecting control in accordance with signals from the ECU. Signals from the ECU
determine the length of time and the timing in which current is applied to the injector. This
in turn, determines the quantity, rate and timing of the fuel that is injected from the
injector.
Q000144E
(4) Engine ECU
a. The engine ECU calculates data received from the sensors to comprehensively control
the injection quantity, timing and pressure, as well as the EGR (exhaust gas
recirculation).
4
2.3 Fuel System and Control System [1] Fuel System
This system comprises the route through which diesel fuel flows from the fuel tank to the supply pump, via the rail, and is injected through the injector, as well as the route through which
the fuel returns to the tank via the overflow pipe.
[2] Control System
In this system, the engine ECU controls the fuel injection system in accordance with the signals received from various sensors. The components of this system can be broadly divided
into the following three types: (1) Sensors; (2) ECU; and (3) Actuators.
(1) Sensors
a. Detect the engine and driving conditions, and convert them into electrical signals.
(2) Engine ECU
a. Performs calculations based on the electrical signals received from the sensors, and
sends them to the actuators in order to achieve optimal conditions.
(3) Actuators
a. Operate in accordance with electrical signals received from the ECU. Injection system
control is undertaken by electronically controlling the actuators. The injection quantity
and timing are determined by controlling the length of time and the timing in which the
current is applied to the TWV (Two-Way Valve) in the injector. The injection pressure is
determined by controlling the SCV (Suction Control Valve) in the supply pump.
Sensor
Crankshaft Position Sensor NE
Cylider Recognition Sensor G
Accelerator Position Sensor
Rail Pressure Sensor
Other Sensors and Switches
Engine Speed
Cylinder Recognition
Load
Actuator
Injector
•Injection Quantity Control
•Injection Timing Control
Engine
ECU
Supply Pump (SCV)
•Injection Pressure Control
EGR, Engine Warning Light
Q000282E
5
3. Construction and Operation
3.1 Description of Main Components [1] Supply Pump (HP3, HP4)
(1) Outline
a. The supply pump consists primarily of the pump body (cam shaft, ring cam, and
plungers), SCV (Suction Control Valve), fuel temperature sensor, and feed pump.
b. The two plungers for HP3 or the three plungers for HP4 are positioned vertically on the
outer ring cam for compactness.
c. The engine drives the supply pump at a ratio of 1:1. The supply pump has a built-in feed
pump (trochoid type), and draws the fuel from the fuel tank, sending it to the plunger
chamber.
d. The internal camshaft drives the two plungers, and they pressurize the fuel sent to the
plunger chamber and send it to the rail. The quantity of fuel supplied to the rail is
controlled by the SCV, using signals from the engine ECU. The SCV is a normally
opened type (the intake valve opens during de-energization).
HP3
Fuel Temperature Sensor
HP4
Fuel Temperature Sensor
SCV
Q000252E
SCV
Q000253E
6
Injector
Rail
Discharge Valve
Intake Valve
Plunger
Intake Pressure
Feed Pressure
High Pressure
Return Pressure
Return Spring
Fuel Tank
Return
Fuel Overflow
Camshaft
Filter
SVC
Regulating Valve
Feed Pump
Fuel Inlet
Intake
Fuel Filter (with Priming Pump)
QD0704E
7
HP3
Pump Body
Ring Cam
SCV
Plunger
Feed Pump
Fuel Temperature
Sensor
Drive Shaft
Regulating
Valv e
Filter
Plunger
Q000254E
8
HP4
SCV
Plunger
Fuel Temperature
Sensor
Ring Cam
Drive Shaft
Filter
Feed Pump
Regulating
Valv e
Pump Body
Plunger
Q000255E
9
(2) Supply Pump Internal Fuel Flow
a. The fuel that is drawn from the fuel tank passes through the route in the supply pump as
illustrated, and is fed into the rail.
Supply Pump Interior
Regulating Valve
Feed Pump
Overflow
Fuel Tank
SCV (Suction Control Valve)
Intake Valve
Pumping Portion (Plunger)
Rail
(3) Construction of Supply Pump (in case of HP3 pump)
a. The eccentric cam is attached to the cam shaft. The eccentric cam is connected to the
ring cam.
Cam Shaft
Eccentric Cam
Ring Cam
b. As the cam shaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves
up and down while rotating.
Q000283E
QD0706E
Plunger
Eccentric Cam
Cam Shaft
Ring Cam
10
QD0727E
c. The plunger and the suction valve are attached to the ring cam. The feed pump is
connected to the rear of the cam shaft.
Plunger A
Ring Cam
Feed Pump
Plunger B
QD0728E
11
(4) Operation of the Supply Pump
a. As shown in the illustration below (in case of HP3 pump), the rotation of the eccentric cam
causes the ring cam to push Plunger A upwards. Due to the spring force, Plunger B is
pulled in the opposite direction to Plunger A. As a result, Plunger B draws in fuel, while
Plunger A pumps it to the rail. In the case of the 4-cylinder engine used with the HP3
pump, each plunger pumps fuel in a reciprocal movement during the 360° cam rotation.
Conversely, in the case of the 6-cylinder engine used with the HP4 pump, 3 plungers
pump fuel in a reciprocal movement for each one rotation of the cam.
Suction Valve
Plunger A
SCV
Plunger B
Delivery Valve
Eccentric Cam
Ring Cam
Plunger A: Complete Compression
Plunger B: Complete Intake
Plunger A: Begin Intake
Plunger B: Begin Compression
Plunger A: Begin Compression
Plunger B: Begin Intake
NOTE:
There are 3 plungers for the HP4.
Plunger A: Complete Intake
Plunger B: Complete Compression
QD0707E
12
[2] Description of Supply Pump Components
(1) Feed Pump
a. The trochoid type feed pump, which is integrated in the supply pump, draws fuel from the
fuel tank and feeds it to the two plungers via the fuel filter and the SCV (Suction Control
Valve). The feed pump is driven by the drive shaft. With the rotation of the inner rotor,
the feed pump draws fuel from its suction port and pumps it out through the discharge
port. This is done in accordance with the space that increases and decreases with the
movement of the outer and inner rotors.
Outer Rotor
Intake Port
from Fuel Tank
to Pump Chamber
Inner Rotor
Discharge
Port
Quantity Decrease
Quantity Increase
Quantity Decrease (Fuel Discharge)
Quantity Increase (Fuel Intake)
(2) SCV: Suction Control Valve (Normally open type)
a. A linear solenoid type valve has been adopted. The ECU controls the duty ratio (the
duration in which current is applied to the SCV), in order to control the quantity of fuel
that is supplied to the high-pressure plunger.
b. Because only the quantity of fuel that is required for achieving the target rail pressure is
drawn in, the actuating load of the supply pump decreases.
c. When current flows to the SCV, variable electromotive force is created in accordance with
the duty ratio, moving the armature to the left side. The armature moves the cylinder to
the left side, changing the opening of the fuel passage and thus regulating the fuel
quantity.
d. With the SCV OFF, the return spring contracts, completely opening the fuel passage and
supplying fuel to the plungers. (Full quantity intake and full quantity discharge)
e. When the SCV is ON, the force of the return spring moves the cylinder to the right, closing
the fuel passage (normally opened).
f. By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the actuation
duty ratio, and fuel is discharged by the plungers.
QD0708E
Exterior View of SCV
Cross-section of SCV
Return Spring
Pump Body
13
SCV
Cylinder
Q000270E
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